Part_3_-_Toe_Seep_Modifications_Plans_and_Specs_4-7-2015.pdf

Summitville Mine Transfer Station

Rio Grande County, CO

November 26, 2012

OWNER’S MANUAL

RJH Consultants, Inc.

Moltz Construction, Inc.

Getting Started

SYSTEM SETUP

1. CAUTION! Before opening & entering the electrical control panel, ensure that the door-mounted main disconnect switch is in the OFF position.

2. WARNING! MAIN DISCONNECT SWITCH upper lugs are always energized.

While this area has a degree of shielding, exercise extreme caution when working near this area. CAUTION! The CONTROL ENCLOSURE may contain a foreign voltage from an external source NOT routed through the Main Disconnect Switch. If so, determine location of source and lock it in the OFF position.

3. CAUTION! VFD units have charged capacitors that hold high voltages even after power has been removed from the unit. Before working in the electrical control panel wait a minimum of 10 minutes after the main power has been removed for these voltages to subside.

4. Check mounting & termination of all electrical equipment. Studs, screws and nuts should all be in place. Wire terminals can vibrate loose during transit to the job site as well as over prolonged periods of operation. Re-torque as needed during initial setup on the job site and periodically thereafter (spring and fall).

5. All wiring must be free of kinks, torn, charred, or missing insulation. If there is evidence of short circuit, over current, or water damage, the pump station must not be placed into service until the cause is identified & corrected.

Common equipment located inside control enclosure:

POWER DISTRIBUTION BLOCK

FUSE BLOCKS (POWER & CONTROL FUSES)

VARIABLE FREQUENCY DRIVE (VFD)

SOFT START

PHASE VOLTAGE MONITOR

DUPLEX OUTLET RECEPTACLE

115 VAC CONTROL TRANSFORMER

24VDC POWER SUPPLY

ALLEN BRADLEY SLC 5/04 PLC

DOOR MOUNTED DISPLAY UNIT

CONTROL RELAYS

DOOR-MOUNTED PUSHBUTTONS AND SELECTOR SWITCHES

CABINET INTERIOR LIGHT FIXTURE

Check that all components are secured in their mountings after shipment.

SYSTEM SETUP

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Common equipment located outside control enclosure:

LIGHTNING ARRESTOR: Check for surge damage, charring or swelling PRESSURE SENSOR: Check for leaks/damage; keep connections clean FLOW SENSOR: Same as pressure sensor PUMP MOTOR(s): Ensure that terminal box covers & coupling guards are in place PRESSURE RELIEF VALVE: Keep discharge piping free from obstruction

5. CAUTION! The pump station and associated piping is under PRESSURE. Close the gate valve to isolate the station from the system and drain the water from the station before adjusting or removing any plumbing, fittings, etc.. Failure to de-pressurize the system may result in INJURY.

6. The pump station electrical control enclosure and/or mounting skid must be electrically connected to EARTH GROUND.

7. ALL ELECTRICAL CONNECTIONS MUST BE MADE IN ACCORDANCE

WITH THE NATIONAL ELECTRICAL CODE AND/OR LOCAL CITY OR

STATE CODES.

SYSTEM CHECK OUT PROCEDURE

This procedure must be performed prior to new system start-up, or for restarting the station after it has been out of service for an extended time.

1. Turn MAIN DISCONNECT switch to the OFF position.

2. HAND/OFF/AUTO (HOA) switches must be in the OFF position.

3. Review SYSTEM SETUP detailed in the previous pages.

4. All PETCOCK VALVES must be CLOSED. Through out the pumping system there may be several drains and vents to check. Locate all open drain valves and plugs and seal them OFF. Common locations for drains are low points, where water can be trapped, such as on the underside of the discharge piping.

SYSTEM START-UP PROCEDURE

After the Check out Procedure, the Station is ready for Start-Up.

1. Turn MAIN DISCONNECT switch to the ON position.

2. Turn PANEL POWER selector switch to the ON position.

3. The DISPLAY UNIT should now be powered-up, displaying the SELECT screen.

NOTE: If the DISPLAY UNIT does NOT power-up, it could mean that the PHASE VOLTAGE MONITOR has cut off power to the controls. This occurs if the incoming power is not in conformity with the settings of the monitor. If the green light on the phase monitor is not illuminated, please call Watertronics.

--- WARNING !! ---

This equipment contains LIFE THREATENING VOLTAGES. Exercise

EXTREME CAUTION when working inside the control panel. Never open the electrical control panel until you have TURNED OFF all power.

4. Upon power-up the DISPLAY UNIT will display a PHASE/VOLTAGE alarm. To clear the alarm, press the red RESET button on the door.

5. After pressing the red reset button on the panel door the alarm alert will stop scrolling in the banner at the top of the SELECT SCREEN and the alarm line will stop flashing.

6. Each motor needs to be jogged to check for proper rotation. Monitoring discharge pressure while running can check submersible pump rotation. If pressure is low, TURN OFF the MAIN DISCONNECT and rotate motor power leads. Reapply power to run the pump and pressure should climb to design point.

7. Turn the HAND/OFF/AUTO (HOA) selector switches to the AUTO position.

-- CAUTION ---

IF THE SYSTEM PRESSURE IS LOW, OR THERE IS A FLOW DEMAND,

THE PUMP STATION MAY START AUTOMATICALLY!

8. The Pump(s) should now sequence ON & OFF depending on water level.

BASIC SYSTEM OPERATION

This Watertronics Pump Station is designed to operate as a pressure start system. When placed in the AUTO MODE, the station’s control system (PLC) responds to the pressure transducer.

As a precautionary measure, the Pump Station is designed to protect itself from potential damage by TURNING OFF if the control system detects an ALARM condition. This condition will be indicated by an ALARM! Message being displayed on the DISPLAY UNIT. Should this situation occur, take the necessary steps to correct the indicated Alarm Condition (Tab 6). When the problem is corrected press the red RESET button on the Electrical Control Enclosure door to clear the alarm.

ALARM CONDITIONS & SHUTDOWNS

There are number of possible causes for Alarm Conditions. Refer to the Troubleshooting Guide section of this manual for detailed explanations. After the cause has been determined, & corrected, reset the station by pressing the red RESET button.

CAUTION! Pump station must never be operated in manual mode as a means of bypassing any alarm protection.

High-High Float Alarm:

The pump station will alarm when the high-high float switch is reached. The second pump will start to attempt to get the water level down.

Low-Low Float Alarm:

When this float stops the station an alarm will be sent and it will continue to stop the station until Stop float is replaced. If this float fails Start float starts and stops station.

Phase / Voltage Alarm:

A Phase / Voltage Alarm will be displayed in the event of a POWER LOSS to the Pump Station or a PHASE LOSS on the AC line.

Overload Pump No. __:

An Overload Alarm will be displayed in the event the OVERLOAD RELAY on the specified pump has TRIPPED due to sensing excessive current being drawn by the pump motor.

PLC Battery Low:

A PLC Battery Low Alarm will be displayed in the event the battery in the PLC needs to be replaced. Contact Watertronics immediately for a replacement battery.

Pressurization Alarm:

This alarm indicates that the Pump Station could NOT reach the FINAL Regulation SET POINT after attempting to pressurize the system.

Final Shutdown Alarm:

The Pump Station has SHUTDOWN and must be MANUALLY RESET.

ALARM CONDITIONS & SHUTDOWNS

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High Temperature Cutout:

When the pump station is in AUTO MODE operation, the THERMAL SENSOR monitors CENTRIFUGAL PUMP temperature. Heat build up exceeding that of normal operation (130 degrees or above) causes sensor contacts to close, signaling the PLC. If the condition does not self-correct within ten seconds, control logic will shutdown the affected pump and displays a High Temp. alarm.

SELECT SCREEN

BANNER